Deployment door for air bag module

Abstract

An occupant safety apparatus (10) is for mounting on an instrument panel (20) of a vehicle (12) which extends generally rearward in the vehicle from the vehicle windshield (22) and which defines a deployment opening (60). The safety apparatus (10) comprises an inflatable protection device (44) having an uninflated condition and an inflated condition. The safety apparatus (10) also comprises an inflator (46) for, when actuated, inflating the protection device (44). A door (70) covers substantially the entire deployment opening (60). The door (70) has a first edge portion (72) disposed closer to the vehicle windshield (22) and a second edge portion (74) disposed farther from the vehicle windshield. A hinge (76) is connected to the second edge portion (74) of the door adjacent the instrument panel (20). The hinge (76) supports the door (70) on the instrument panel (20) for pivotal movement about the hinge between a closed condition covering substantially the entire deployment opening (60) and an open condition in which the second edge portion (74) of the door remains connected with the hinge and adjacent the instrument panel and the first edge portion (72) of the door is spaced farther from the instrument panel than in the closed condition.

What is claimed is: 
     
       1. An occupant safety apparatus for mounting on an instrument panel of a vehicle, the instrument panel extending generally rearward in the vehicle from the vehicle windshield and defining a deployment opening, said safety apparatus comprising: an inflatable vehicle occupant protection device having an uninflated condition and an inflated condition, said occupant protection device restraining a vehicle occupant while in said inflated condition;   an inflator for, when actuated, inflating said protection device;   a door for covering substantially the entire deployment opening in the instrument panel, said door having a first edge portion disposed closer to the vehicle windshield and a second edge portion disposed farther from the vehicle windshield; and   a hinge connected to said second edge portion of said door adjacent the instrument panel, said hinge supporting said door for pivotal movement about said hinge relative to the instrument panel between a closed condition covering substantially the entire deployment opening and an open condition in which said second edge portion of said door remains connected with the hinge and adjacent the instrument panel and said first edge portion of said door is spaced farther from the instrument panel than in the closed condition,   said door having a first portion which may engage the vehicle occupant and overlie a chin and neck portion of the vehicle occupant as said door moves to said open condition, said door further having a second portion for directing said occupant protection device away from the chin and neck portion of the vehicle occupant when said door overlies the chin and neck portion of the vehicle occupant.   
     
     
       2. An apparatus as set forth in claim 1 wherein said second edge portion of said door is a rear edge portion of said door and said inflator is actuatable to inflate said protection device in a generally upward direction in the vehicle. 
     
     
       3. An apparatus as set forth in claim 2 wherein said first edge portion of said door is a forward edge portion of said door and pivots rearward and upward during movement between the closed condition and the open condition. 
     
     
       4. An apparatus as set forth in claim 1 wherein said second edge portion of said door is a lower edge portion of said door and said inflator is actuatable to inflate said protection device in a generally rearward direction in the vehicle. 
     
     
       5. An apparatus as set forth in claim 4 wherein said first edge portion of said door is an upper edge portion of said door and pivots rearward and downward during movement between the closed condition and the open condition. 
     
     
       6. An apparatus as set forth in claim 1 further comprising a tear seam releasably connecting said first edge portion of said door with the instrument panel. 
     
     
       7. An apparatus as set forth in claim 1 wherein said hinge is molded as one piece with said door. 
     
     
       8. An occupant safety apparatus for mounting on an instrument panel of a vehicle, the instrument panel having an upper portion extending generally rearward in the vehicle from the vehicle windshield and defining a deployment opening facing generally upward in the vehicle, said safety apparatus comprising: an inflatable vehicle occupant protection device having an uninflated condition, a partially inflated condition, and a fully inflated condition;   an inflator for, when actuated, inflating said protection device in a generally upward direction through the deployment opening;   a door for covering substantially the entire deployment opening, said door having a forward edge portion and a rearward edge portion; and   a hinge connected to said rearward edge portion of said door adjacent the upper portion of the instrument panel, said hinge supporting said door for pivotal movement about said hinge relative to the instrument panel between a closed condition covering substantially the entire deployment opening and an open condition in which said rearward edge portion of said door remains connected with the hinge and adjacent the upper portion of the instrument panel and said forward edge portion of said door is spaced farther from the instrument panel than in the closed condition,   said door engaging a chin portion of a vehicle occupant while said occupant protection device is in said partially inflated condition, said door having a portion for directing said occupant protection device away from the chin portion.   
     
     
       9. An apparatus as set forth in claim 8 wherein said forward edge portion of said door pivots rearward and upward during movement of said door between the closed condition and the open condition. 
     
     
       10. An apparatus as set forth in claim 8 further comprising a tear seam releasably connecting said forward edge portion of said door with the instrument panel. 
     
     
       11. A vehicle occupant safety apparatus for mounting on a portion of a vehicle instrument panel extending generally vertically in the vehicle and defining a deployment opening, said safety apparatus comprising: an inflatable vehicle occupant protection device having an uninflated condition, a partially inflated condition, and a fully inflated condition;   an inflator for, when actuated, inflating said protection device in a generally rearward direction through the deployment opening;   a door for covering substantially the entire deployment opening, said door having an upper edge portion and a lower edge portion; and   a hinge connected to said lower edge portion of said door adjacent the instrument panel portion, said hinge supporting said door for pivotal movement about said hinge relative to the instrument panel portion between a closed condition covering substantially the entire deployment opening and an open condition in which said lower edge portion of said door remains connected with the hinge and adjacent the instrument panel portion and said upper edge portion of said door is spaced farther from the instrument panel than in the closed condition,   said door having an inner surface adjacent said occupant protection device and an outer surface opposite said inner surface, said inner surface of said door directing said occupant protection device vertically away from said hinge when said occupant protection device is in said partially inflated condition, said outer surface of said door contacting a chin portion of a vehicle occupant when said occupant protection device is in said partially inflated condition.   
     
     
       12. An apparatus as set forth in claim 11 wherein said upper edge portion of said door pivots rearward and downward during movement of said door between the closed condition and the open condition. 
     
     
       13. An apparatus as set forth in claim 11 comprising a tear seam releasably connecting said upper edge portion of said door with the instrument panel.